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1 PREMISE
This Functioning and Maintenance Manual (hereinafter named Manual) was written according to
par. 1.7.4 of the E.C.C. Directive 891391/ C.E.E., par. 1.7.4 of D.P.R. 459 of 24 July 1996
considering the normal operating conditions of the machine, with the purpose to inform, as set out
in the instructions attached to the machine itself, the operators/users on the risks deriving from its
use.
Note: the Manual is an integral part of the machine, must be carefully read before any operation is
carried out and is to be kept for future reference.
1.1 CE MARKING
The CE marking has been applied according to the Directive of the Board 93/68/CEE (GUCE L 220
of 30/08/1993), and to the annex. III of Directive 89/392 (GUCE L 183 of 23/06/1989) and to any
later modifications of it.
The documentation meant as technical file in compliance with the CE statement of conformance for
this machine was drawn up according to the provisions set out in the Annex. V of ECC Directive
89/392 and its modifications, as well as in full complance with D.P.R. 459 of 24 July 1996, which
takes in the above-mentioned EU Directive, and is kept by the Manufacturer.
1.2 NOISE
The noise made by the machine is: Leq=<80dB.
Based on the results assessed according to D.L.vo 277/91 and the provisions of D.L. 459/96, a list
of obligations to be fulfilled by employers, executives and operators must be drawn up according to
the degree of exposure to the noise by the workers.
The noise made by the machine is within range 1, wherein the noise risk is considered null.
1.3 SAFETY WARNINGS
These instructions contain basic warnings to be complied with during installation, operation and
maintenance. Therefore, these instructions must absolutely be read by the assembler, the technical
staff and by operators before assembly and startup, and must be kept available at any time on the
site where the machine or plant is used.
1.4 PERSONNEL'S QUALIFICATION AND TRAINING
The staff in charge of operation, maintenance, inspection and assembly must be qualified. The plant
manager must precisely set out any responsibilities, qualifications and control related to the
personnel. If the personnel is not adequately informed, it is to be trained and informed. This can be
made, if necessary, by the manufacturer/supplier on behalf of the machine user. Moreover, the user
must check that the contents of these instructions is fully understood by the personnel.
1.5 TRANSPORT
The customer must be aware of the use of lifting devices and harnessing techniques in compliance
with the relevant rules concerning accident prevention.
See par. 5.1 (Packing and transport).
1.6 STARTUP, USE AND MAINTENANCE
The customer must be aware of the features and working characteristics of the plant in which the
pump is to be fixed. Moreover, he must get information on the pump functioning in advance, be
informed of the safety warnings, startup and maintenance instructions.
The service staff shall be instructed on the use of the pump and related plant.
1.7 REPAIRING
The customer shall gather in advance detailed information on the pump, as illustrated in the
repairing instructions.
1
L&M pumps
The service staff shall be trained and repairing work shall be monitored.
1.8 RISKS IN THE EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS
Non-compliance with safety warnings may put people, the environment and the machine itself at
risk.
In particular, for instance, non-compliance may lead to:
Failure to perform important functions by the machine/plant.
Malfunctioning of the methods prescribed for maintenance and repairing.
Risk vs. people due to electric, mechanical and chemical effects.
Environmental risks due to leakage of harzardous substances.
1.9 SAFE WORKING
It is necessary to observe the safety warnings set out in these instructions, the national rules on
accident prevention and possible regulations concerning the work, service and safety of the
operator.
1.10 WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER
In the event that cold or hot parts of the machine may lead to risks, the customer must
provide protection against accidental contact (according to European regulation EN 563).
The protection against accidental contact on the moving parts (e.g. joint) may not be
removed when the machine is working.
Leakage of hazardous materials (e.g. from shaft seal) such as explosive, poisonous and
overheated materials, shall be disposed of without causing danger to both people and the
environment. Provisions of the law shall be compiled by.
1.11 WARNINGS CONCERNING SAFETY DURING MAINTENANCE, INSPECTION AND
ASSEMBLY
The customer shall make it sure that any maintenance, inspection and assembly operations are
carried out by authorized, specialized and qualified staff, and that said personnel must be adequately
informed by fully-detailed service instructions.
The work on the machine shall be executed only when the machine is not working. The machine
shall not be under pressure and shall be cooled. The procedure for machine stop shall be absolutely
complied with.
Those pumps or units feeding hazardous materials shall be decontaminated.
After work is completed, every safety and protection devices shall be immediately refitted and
reactivated.
Before restarting, the provisions of the chapter Startup shall be compiled by.
1.12 TRANSFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS
Any transformation or modification of the machine are allowed only by prior agreement with the
manufacturer. Original spare parts and authorized accessories are required for safety. The use of
other parts releases any responsibility for related damages.
1.13 PROPER USE
The safety of the machine is guaranteed only when the use of the machine is carried out according
to the rules.
This machine has been designed considering its nominal working performance. Any indication
concerning the nominal working performance is to be meant as a limit value, and shall not be
exceeded in any case.
L&M pumps
2 FUNCTIONING
A progressing cavity pump is a rotating volumetric pump. The main parts of the system are a rotary
part called ROTOR and a fixed part called STATOR .
The rotor is a round thread screw with a very large pitch, a deep thread and a small core diameter.
The stator is double-threaded and has a pitch which is double compared to the rotor, so that between
the stator and the rotor there are delivery chambers. These move continuously from the inlet side
towards the outlet when the rotor is spinning inside the stator.
In progressing cavity pumps the axis of rotation of the rotor A does not coincide with the axis of
rotation of the motor. The rotor is driven by a double-joint shaft. This shaft absorbs eccentric
motions and shifts axial stresses towards the motor shaft.
L&M pumps
Self-priming, with a min. suction of 4 mt, depending on the number of stages and rpm of the
pump.
Pumping of non-homogeneus products, containing gas and abrasive or solid and fibrous
material in the fluid.
Pumping of very high viscous liquids.
Dosage of liquids.
No inlet or delivery valves.
Centrifugation-free pumping with low tension stress in the pumped material.
High pumping pressure (6 BAR for each stage). Pumps may have one up to four stages,
according to the pressure required:
3.2 CLASSIFICATION
Progressing cavity pumps are divided into two main categories, according to the coupling between
pump and motor:
Progressing cavity pumps WITH BEARING HOUSING.
Progressing cavity pumps CLOSED COUPLED.
3.3 MOTORS
Motors can be of different kinds; the pump can be fitted to:
Electric motors
Hydraulic motors
Gearmotors
Torque converters
L&M pumps
4.1 ROTOR
The rotor may be made of different materials, such as carbon steel and stainless steel. It may also be
coated with hardening surface treatments such as chromium plating, ceramic treatment, gas and ion
nitriding, etc.
4.2 STATOR
The stator is built with a steel pipe internally coating with elastomeric material, chemically
compatible with the properties of the fluid to be pumped.
It may be made with different elastomers:
Class
T4
T5
T6
MST C
135
100
85
Class
Stator
T4
VITON
T5
EPDM
T6 NBR - SBR
MST: Maximum surface temperature allowed for machines of Group II (Cenelec standard EN
50014).
Note: It is possible to manufacture teflon stators for special applications.
4.3 COUPLINGS
4.3.1 BEARING HOUSING COUPLING
Using the bearing housing coupling the pump is linked to the motor by the male shaft, and it is
mounted on a cast iron support through rolling bearings.
This configuration allows optimal resistance to the axial thrust towards the motor in those models
working under high pressure. The choice of the motor in this case is not affected by axial thrust.
The final coupling between motor and male shaft is made by elastic joints with a protective case.
L&M pumps
Note: It is possible, for a special series of feedbox pumps, to link the propeller shaft directly to an
angular worm screw gearmotor, without any support.
L&M pumps
L&M pumps
Stator: In case of prolonged stop, the rotor may permamently buckle the stator on the contact
surface (compression-set). This requires a greater pickup torque. Therefore, remove the
stator, pack it in order to shelter it from light and air, and store it in a cool, dry place.
Rotor: Rest it on wooden blocks and cover it for protection against mechanical damage.
Shaft packing: Remove the gland, and grease the shaft.
Stainless steel parts: No protection needed.
Other non-painted pump parts: Grease.
Motors: see manufacturers instructions.
L&M pumps
Nonetheless, it is possible that during the positioning on the floor a misalignment may occur,
therefore it is necessary to remove the joint cover and check its alignment by means of a ruler
before startup. If the foundation is not properly leveled, the base may buckle. The tolerances usually
allowed in joints used by the company are:
Allowed radial variation = 1%
Allowed angular variation = 1
6.1.3 DIRECTION OF ROTATION
The direction of pump rotation is shown on the label pump and described on the confirmation
order.
The direction of pump rotation sets the direction of the flow through the progressing cavity pump.
Any different setup must be agreed with the supplier and approved by the same.
By changing the direction of pump rotation, the product flow reverses.
If the pump turns clockwise, seen from the motor side, it intakes from the orifice at the end and
delivers from the middle one; if the pump turns counterclockwise it intakes from the middle orifice
and delivers from the one at the end (see below).
Usually, the pump can work in both directions, be it mounted with packing or with a mechanical
seal (unless it uses omokinetic joints which allow just one direction).
It is advisable, though, to use the pump turning counterclockwise to prevent that the packing rings
(or the mechanical seal) or other parts were subject to high pressure that could be difficult to
monitor.
The pumps with a mechanical seal, though reversing, shall always turn in the direction indicated on
the pump label.
This direction of rotation shall be preset upon the order while the seal assembled shall be preset at
the factory.
Contact L&M if you need to change the direction of rotation for pumps that use mechanical seal.
IMPORTANT:
In close coupled versions, it is necessary to check periodically that the shaft grub screw were well
tightened and fits properly in the propeller shaft cavity, especially if the pump is employed in both
directions. To this purpose, see par. 6.1.2.1 of this Manual.
6.2 PIPE ASSEMBLY
6.2.1 IMPORTANT PREMISE
Intake and outlet diameters must be adequate, according to viscosity and delivery involved.
Accurately clean the pipes before connecting them to the pump.
Pipes must be connected to the pump so that no external force may be applied to the pump
itself.
Fit adequate compensators between pump and pipes to protect the pump from vibrations
which may damage the pump body.
Intake and outlet pipes shall be fitted so that, the pump is not working, there is some fluid
upstream and downstream, in order to ensure that there is always enough fluid in the pump
to provide lubrication at startup.
Minimize the air intake in the body pump.
Note: In case fluxed packing glands or fluxed mechanical seals or quenches were used, the feeding
system connections and system tuning must to be carried out prior to the first startup.
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L&M pumps
PUMP
010
015
020
030
040
050
053
055
060
065
080
120
150
200
250
300
LENGTH L
1 STAGE 2 STAGE 3 STAGE 4 STAGE
80
80
160
110
170
360
160
300
200
420
260
530
530
270
550
980
440
630
1230
320
630
440
840
500
540
540
1050
2110
660
1260
820
1580
-
7 STARTUP
IMPORTANT
Never operate the pump when dry - this is mandatory, otherwise the stator, made of
elastomeric material will overheat and may burn. A few seconds are enough to cause
damage to the stator.
The eccentric screw pump is of the volumetric kind, therefore it shall NEVER be
operated with a closed delivery valve. Since the theoretical pressure is infinite, this would
cause excessive stress with partial or total damage to the pump or piping.
10
L&M pumps
L&M pumps
7.3.1.2 ROTOR
After the stator has been disassambled, rest the rotor on wooden blocks and cover it to prevent
damage.
Before reassembly, degrease and clean the rotor to prevent conflicts with the stator material or with
the product to be pumped.
8 MAINTENANCE
IMPORTANT: All maintenance and cleaning operations must be performed with the
machine at a standstill and cut out from any energy source.
After a stop and before restarting, the machine must be inspected to determine the cause of the stop
command, and act with appropriate measures in order to prevent that from happening again.
The inherent vibrations of a progressing cavity pump are below 2.5 m//sec, therefore they hardly
cause risk or trigger possible failures. The vibrations, though, may lead to the loosening of the
screws of the pump. It is therefore essential to regularly check the tightening of them.
8.1 SUPERFICIAL CLEANING
It is important to schedule regular cleaning operations, depending on the liquid to be pumped. The
pump may be cleaned:
Through the cleaning windows if present on the pump body.
Manually, disassembling the pump
Automatically (CIP) for pumps with suitable connectors.
8.2 STATORS AND SEALING SYSTEMS
8.2.1 STATORS
Approx. every 900 hours of operation, it is necessary to check the wear, especially for the stator and
the sealing system (packing or mechanical seal).
The frequency of control operations will be determined according to the wear of both of them, not
exceeding anyway 1500 working hours.
8.2.2 SEALS
8.2.2.1 PACKING SEALS
Packing seals limit the leakage of product, but do not prevent it entirely. A small leakage is
necessary to prevent excessive friction and subsequent possible overheating.
At startup, after replacement, tighten the gland bush lightly until it is set and in ideal working
conditions (for 10-15 min.), then tighten it more strongly to obtain the smallest possible leakage.
FUNCTIONING ERRORS AND THEIR CONSEQUENCES
In case the pack were excessively compressed, the following damages may arise:
Dry working
Burnt pack
Scored shaft (with subsequent leakage of fluid).
NOTE: The packing seal is in optimal working condition if constantly damped by the product to be
pumped.
8.2.2.2 SINGLE MECHANICAL SEAL
The type and brand of the mechanical seal used is specified in the order confirmation. In case of
significant leakage, check the surfaces of the seal faces and seat. Replace them if necessary.
12
L&M pumps
Molycote VN 2461 C
Bearings
Agip MU3
8.4.2 BEARINGS
The male shaft bearings are greased at L&M. In case they were removed, their seat shall be filled
with grease according to the table above.
8.4.3 PROPELLER SHAFT JOINTS
Pin joints with sleeve are to be periodically lubricated.
Moreover, every time parts were replaced with original spare parts, their grease shall be replaced.
IMPORTANT: The pumps that uses sleeves over joints for food are supplied with food-compatible
grease.
8.4.4 MOTOR VARIATOR
See Service Manual
8.5 MALFUNCTIONING
Below you can find a synthetic table
Malfuntioning References:
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L&M pumps
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
A
X
X
X
X
X
X
X
A
B
C
D
E
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
G
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
F
G
H
I
J
J POSSIBLE CAUSE
New stator and rotor are stuck together
Faulty electrical contact
Excessive delivery pressure
Unknown matter in the pump
High temperature, the stator squeezed
Stator of wrong material. Check the order
Product granulometry too high.
X The product sediments when the pump is stopped
Air leakage at intake
Difficult intake
Air intake from seal or packing
X Too Low speed
Wrong direction of rotation
X Available NPSH below required
X The pump is working dry
X The stator is faulty burned-over
X Spoilt stator. Check rubber
X Faulty rotor
Faulty connecting rod
The pump is not aligned to the elastic joint
Broken connecting rod
Spoilt bearings
Too high speed
X Excessive viscosity
X The gland needs to be adjusted
X Inadequate sealing system
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L&M pumps
22) Replace bearings, lubricate and tight.
23) Lower rpm through variator.
24) Check viscosity and compare it with the order.
25) Check specific weight and compare it with the order.
26) Choose a different mechanical seal or packing.
Note: For any query, please contact L&M or our local agent.
NOTE: Certain types of stators have at their end an integrated sealing profile.
In this case no ORing washers are needed neither at the union side nor at the pump body side. In
any other case, they shall be replaced every time the parts are disassembled.
WARNING: Do not tighten the pump body threaded cap too strongly, since its cone-shaped thread
could damage the pump body itself. The tightening torque is about 40-50 Nm. Do not over-tighten
screws and tie rods. See table below:
Screw
Dia
Torque (Nm)
15
30
45
15
75
80
100
12
L&M pumps
023
021
024
022
019
017
016
018
015
013
014
W
L01
16
L&M pumps
015
G02
G06
G04
G01
G05
17
G03
016
L&M pumps
W01
007
002
008
010
012
011
L01
006
004
005
003
L&M pumps
L02
L06
L09
L04
L05
L10
L11
L08
L07
L03
Stand:04.2005
19
L&M pumps
Pos.
Description
Qt.
L01
Coupling Flange
L02
Bering Housing
L03
Drive Shaft
L04
Bearing
L05
Distance Sleeve
L06
Key
L07
Key
L08
Circlip
L09
Oil Seal
L10
Oil Seal
L11
Screw
002
Lipsea Hhousing
003
Bearing Housing
004
Drive Shaft
005
Circlip
006
Oil Seal
007
Oil Seal
008
Bearing
009
Greace Screwl
010
O-Ring
011
Screw
012
Washer
013
Nut
014
Washer
015
016
Rotor
017
Stator
018
Screw
019
020
Support
021
Screw
022
Washer
023
Screw
024
Washer
G01
Rubber Sleeve
G02
Camping Ring
G03
O-Ring
G04
Pin
G05
Sleeve
G06
Retaining Ring
W01
Lipseal
20
L&M pumps
SUMMARY
1 PREMISE
1.1 CE MARKING
1.2 NOISE
1.3 SAFETY WARNINGS
1.4 PERSONNEL'S QUALIFICATION AND TRAINING
1.5 TRANSPORT
1.6 STARTUP, USE AND MAINTENANCE
21
1
1
1
1
1
1
1
L&M pumps
1.7 REPAIRING
1.8 RISKS IN THE EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS
1.9 SAFE WORKING
1.10 WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER
1.11 WARNINGS CONCERNING SAFETY DURING MAINTENANCE, INSPECTION AND ASSEMBLY
1.12 TRANSFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS
1.13 PROPER USE
1.14 SPECIFIC WARNINGS FOR PROGRESSING CAVITY PUMPS
2 FUNCTIONING
3 BRIEF DESCRIPTION OF THE PRODUCT
3.1 MAIN TECHNOLOGICAL FEATURES OF PROGRESSING CAVITY PUMPS
3.2 CLASSIFICATION
3.3 MOTORS
4 COMPONENTS OF THE PRODUCT
4.1 ROTOR
4.2 STATOR
4.3 COUPLINGS
4.3.1 BEARING HOUSING COUPLING
4.3.2 CLOSED COUPLING
4.4 CONNECTING ROD JOINTS
4.5 SEALING SYSTEMS
4.6 ACCESSORIES
4.6.1 DRY-RUN PROTECTION
4.6.2 PROTECTION AGAINST DELIVERY OVERPRESSURE
4.6.3 RETURN VALVE IN DELIVERY
4.6.4 ELECTRIC BOARD
5 PACKING, TRANSPORT, STORAGE
5.1 PACKING AND TRANSPORT
5.2 STORAGE
6 ELECTRIC CONNECTION PIPELINE CONNECTION
6.1 INSTALLATION OF MOTOR
6.1.1 ELECTRIC CONNECTION
6.1.2 PUMP-MOTOR COUPLING
6.1.2.1 CLOSE COUPLED VERSION
6.1.2.2 BEARING HOUSING VERSION (WITH ELASTIC JOINT)
6.1.3 DIRECTION OF ROTATION
6.2 PIPE ASSEMBLY
6.2.1 IMPORTANT PREMISE
6.2.2 MAX ALLOWED PRESSURE
6.2.3 USEFUL ADVICE
7 STARTUP
7.1 ADVICE FOR OPTIMAL OPERATION
7.2 PUMPS FOR FOOD
7.2.1 WHEN TO PERFORM CLEANING
7.2.2 CIP CYCLE
7.3 TEMPORARY REST
7.3.1 PROCEDURES
7.3.1.1 STATOR
7.3.1.2 ROTOR
8 MAINTENANCE
8.1 SUPERFICIAL CLEANING
8.2 STATORS AND SEALING SYSTEMS
8.2.1 STATORS
8.2.2 SEALS
8.2.2.1 PACKING SEALS
8.2.2.2 SINGLE MECHANICAL SEAL
8.2.2.3 MECHANICAL SEALS FOR VERTICAL PUMPS
8.3 CONTROL AND REPLACEMENT OF ARTICULATED JOINTS
8.4 LUBRICATION
8.4.1 IN GENERAL
8.4.2 BEARINGS
8.4.3 PROPELLER SHAFT JOINTS
22
1
2
2
2
2
2
2
3
3
3
3
4
4
4
5
5
5
5
5
6
6
6
6
6
7
7
7
7
7
8
8
8
8
8
8
9
9
9
10
10
10
11
11
11
11
11
11
11
12
12
12
12
12
12
12
12
13
13
13
13
13
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L&M pumps
8.4.4 MOTOR VARIATOR
8.5 MALFUNCTIONING
8.5 MALFUNCTIONING
9.1 Sectional Drawing
9.2 Sectional Drawing Joint
9.3 Sectional Drawing Seal
9.4 Sectional Drawing Bearing Housing
10.1 Parts List
13
13
135
16
17
18
19
20
23